Measurement devices with memory tags and methods thereof

ABSTRACT

A downhole measurement device includes one or more sensors configured to measure a parameter in a well; a plurality of memory tags for storing measurement data from the one or more sensors; and an ejection module configured to release one of the plurality of memory tags upon a predetermined condition. A method for monitoring a well includes deploying of a measurement device having one or more sensors and a plurality of memory tags into a wellbore; obtaining measurement data of the parameter using the one or more sensors; writing the measurement data to one of the plurality of memory tags; releasing the memory tag having the measurement data; allowing the memory tag having the measurement data to be carried by a flow in the wellbore uphole; reading the measurement data from the memory tag having the measurement data at a location remote from the downhole measurement device.

CROSS REFERENCE TO RELATED APPLICATIONS

The invention claims benefits of U.S. Provisional Application No. 61/301,480, filed on Feb. 4, 2010, the disclosure of which is incorporated by reference in its entirety.

BACKGROUND OF INVENTION

1. Field of the Invention

The invention relates generally to the measurements of wellbore conditions in downhole applications, and more particularly to the use of well-monitoring systems that record downhole data and communicates that data to the surface of a well system.

2. Background Art

In oil and gas production, it is important to monitor downhole data, such as pressure, temperature, flow and other fluid or reservoir properties. These measurements may be obtained by various sensing devices, either using permanent completion deployed sensors or intervention based logging tools on an episodic basis. These sensors may provide key data to enable development of fields, managing and exploiting reserves in place to maximize production and recovery. Challenges exist where the wells or reservoirs become difficult to reach with permanent completion sensors because of multiple stages in the well. In addition, downhole sensors that are installed will fail over time and intervention-based solutions are very costly, especially on small platforms or subsea wells.

In most cases, permanent downhole gauges or sensors may be not installed as part of the completion for many reasons, e.g. cost, geometrical compatibility, reliability, and temperature of the well to name a few. However, legal (regulatory) or reservoir requirement may demand data from wells at some stage of operations. These data may be obtained with memory gauges or logging tools coupled with various sensors that are configured to report on the performance of a well. When sensors are not permanently installed with completion, data needed to meet these legal or regulatory requirements may be obtained, for example, using slickline memory gauges deployed in a well for a period of time, and then retrieved to download the data. Additionally, another solution is to use retrofit technology to deploy sensors on slickline, wireline and or coiled tubing into the well.

Many of these technologies have safety risks with regards to intervention in a well, are costly, and have limited data capability. As existing oil wells begin to either deplete or water out, there is a need to close off the existing production zones and drill a secondary leg in the same well. This secondary leg, drilled to a new pocket of oil and or gas, is known as a lateral or multi-lateral leg and is accomplished by through tubing drilling and completion. The through tubing drilling and completion makes use of the existing well upper casing and upper completion sections and offers additional drainage point(s) from the same well, considerably lowering an operator's CAPEX and OPEX costs.

With lateral or multi-lateral well construction, obtaining measurements from a new lateral section in an existing well may pose a difficult task for intervention logging tools. The tools may have a difficult time entering the new lateral section in order to obtain reservoir and/or production measurements. Additionally, it is not possible to run a conventional permanent sensor as the existing completion is not removed and therefore limits the size of what can be run in hole. In some cases, a new completion of a much smaller diameter may be run through the existing upper completion. However, this new completion may not be tied back or coupled to the surface infrastructure.

Therefore, there is still a need for systems and methods that can be used to monitor or measure conditions in a wellbore, especially in newly developed wells, such as laterals or multi-laterals.

SUMMARY OF INVENTION

One aspect of the invention relates to downhole measurement devices. A downhole measurement device in accordance with one embodiment of the invention includes one or more sensors configured to measure a parameter in a well; a plurality of memory tags for storing measurement data from the one or more sensors, wherein the plurality of memory tags are configured to be carried by a fluid flow uphole; and an ejection module configured to release one of the plurality of memory tags upon a predetermined condition.

Another aspect of the invention relates to methods for monitoring a well or fluid parameter in a wellbore. A method in accordance with one embodiment of the invention includes: deploying of a downhole measurement device having one or more sensors and a plurality of memory tags, wherein the deploying is by allowing the downhole measurement device to be carried by a fluid into the wellbore; obtaining measurement data of the parameter using the one or more sensors; writing the measurement data to one of the plurality of memory tags; releasing the memory tag having the measurement data; allowing the memory tag having the measurement data to be carried by a flow in the wellbore uphole; reading the measurement data from the memory tag having the measurement data at a location remote from the downhole measurement device.

Other aspects and advantages of the invention will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein reference numerals denote corresponding elements. It should be understood, however, that the accompanying drawings illustrate only the various implementations described herein and are not meant to limit the scope of various technologies described herein. The drawings are as follows:

FIG. 1 shows a schematic of a prior art well monitoring system having a sensor in a wellbore.

FIG. 2 shows a schematic of a measurement device according to one embodiment of the invention.

FIG. 3 shows a schematic of a measurement device engaged in a completion nipple or other profile, according to one embodiment of the invention.

FIG. 4 shows a schematic of multiple measurement devices deployed in a wellbore according to one embodiment of the invention.

FIG. 5 shows a schematic of a self-propelled measurement device according to one embodiment of the invention.

FIG. 6 shows a flow chart illustrating a method for monitoring and collecting well parameters by using a downhole measurement device according to one embodiment of the invention.

DETAILED DESCRIPTION

Embodiments of the invention relate to methods and systems for measurements of well conditions or parameters using sensor devices deployed from the surface. Methods and systems of the invention are particularly useful when laterals or multi-laterals are developed to reach new production zones. In such laterals or multi-laterals, permanent sensors are often not installed due to technical difficulties. Using embodiments of the invention, well conditions and parameters may be monitored without permanently installed sensors.

In the following description, numerous details are set forth to provide an understanding of some illustrative embodiments of the present disclosure. However, it will be understood by those skilled in the art that various embodiments of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible without departing from the scope of the invention.

In the specification and appended claims the terms “memory tag” is used to mean an electronic chip that has a memory for storing data. Any memory tag suitable for storing information may be used with embodiments of the invention, such as RFID tags. A memory tag may further include an antenna coil and a power supply circuit such that in use the memory tag may be powered by inductive coupling. A memory tag may also have a sensor for the receipt of transmitted signals, a processor for processing the received input signals, and a modulation circuit for the overlay of output signals onto the power supply circuit. A read/write device may be used to communicate with a memory tag. The read/write device may have a signal generator, an antenna coil and a power supply circuit for powering the memory tag by inductive coupling. The read/write device may further include a light emitter for emission of a light carrying the input signals to the memory tag, and a demodulation circuit for retrieval of the output signals from the inductive coupling. The term “sensor” is used to mean any device for measuring various properties in the well, such as pressure, fluid flow rates, temperatures, vibration, composition, fluid flow regime, and fluid holdup.

FIG. 1 shows an example of a sensor installed in a wellbore, as disclosed in U.S. Pat. No. 7,140,434, issued to Chouzenoux et al. As showed in FIG. 1, a sensor is installed in an underground well having a production tubing 38 therein. The sensor comprises a sensor body 11 that can be installed in a hole formed in the casing 18 so as to extend between the inside and outside of the casing 18; sensor elements located within the body and capable of sensing properties of an underground formation 10 surrounding the well; and communication elements 66 located within the body and capable of communicating information between the sensor elements and a communication device 68 in the well; wherein the sensor body 11 also includes a portion that can be sealed to the casing or tubing to prevent fluid communication between the inside and the outside of the casing 18 through the hole when the sensor body is installed therein. The sensors can include pressure, temperature, resistivity, conductivity, stress, strain, pH and chemical composition sensors.

To obtain downhole data, such as pressure, temperature, flow, and other fluid or reservoir properties, a permanent or fixed completion deployed sensors or through intervention based logging tools are conventionally used. Some measurement tools may be installed in the well permanently for long term monitoring, while others are run into the well during an intervention to obtain temporary measurements.

As noted above, when new laterals are developed, it is impractical to deploy permanent sensors in the new legs and the intervention approach is costly. Embodiments of the invention provide more convenient approaches to monitoring and measuring well conditions, especially for wells (e.g., new laterals or multi-laterals) where deployment of permanent sensors with completion tubing is impractical.

Some embodiments of the invention relate to deployable measurement devices that can be sent into wellbores from the surface to monitor or measurement wellbore conditions or fluid/reservoir properties. These measurement devices will then record such measurements on memory tags (such as RFID tags) and send those tags uphole. For example, a measurement device in accordance with embodiments of the invention may include a chamber housing memory tags (e.g., RFID tags) and an ejection mechanism (which may be an electrical, hydraulic, or mechanical ejection mechanism) to eject or release those data-containing tags into the flow. These devices may include sensors (e.g., pressure and/or temperature sensors) or some other sensing devices for measuring downhole conditions.

After the sensors make measurements, the devices then write (record) the measured data onto one or more memory tags. Such measurements and recordings may occur, for example, at a predetermined time or under a preset condition. Once this operation is completed, the device may eject or release the memory tag (e.g., an RFID tag), e.g., from an ejection carrier, whereby the tags are carried toward the surface with the flow of oil and/or gas. The memory tags may pass a reader located either on the surface or along the flow line. The reader may automatically upload the acquired data and send the data to surface. This process may take place continuously until the memory tags have been exhausted in the device or the batteries have been expended, whereupon another device may be sent downhole to continue the process.

Event logic can also be built into the devices. The event logic, for example, may be programmed to obtain high frequency data when a change in production occurs, automatically eject the memory tag (e.g., RFID tag) upon stabilization of the event, and then go back to the original logic. This process may be referred to as delta event management.

The sensors and/or event logic components may be MEMS (microelectromechanical systems) or SOI (silicon-on-insulator) devices. The number of logging of events can essentially be unlimited. Some embodiments of the device may be self-programmable or able to be trained.

Some embodiments of the invention are illustrated in FIG. 2 through FIG. 5. The illustrations are meant to demonstrate how a well measurement device may be shaped, how the various components may fit inside the device, or how the device(s) may be placed in a well or a lateral. One skilled in the art would appreciate that these are for illustration only and are not meant to limit the scope of the invention.

Referring to FIG. 2, which shows an exemplary measurement device in accordance with one embodiment of the invention. Such a device may be used as a retrievable retrofit measurement device deployed in tubing or casing. As shown, the measurement device 200 may be in the form of a flow through plug 202, which includes a hallow channel allowing fluids to flow therethrough. In accordance with embodiments of the invention, such a flow through plug 202 may be deployed to latch onto a tubing or casing 203 via lock mandrels or dogs 201. The measurement device 200 may include an ejection capsules 204 containing RFID tags or memory tags, a long life battery 205, downhole reference clock/counter 206, which may have time stamping capabilities, and one or more pressure, temperature, or other sensors or a combination of sensors 207.

The flow through plug 202 may be dropped or inserted into the well from the surface (e.g., through a Christmas tree) and be allowed to drop down to the bottom of the well or to set or engage with the surrounding tubing or casing 203 via lock mandrels or dogs 201. The measurement device may be lodged in a nipple profile or an independent anchor at a predetermined location or be deployed at an appropriate depth and held in place with a lock mandrel or dog 201 until retrieval is required. The device may have built-in intelligence for depth recognition, or for finding or steering its way into a multi lateral leg. The measurement device may be run by battery or downhole power generation.

The device may comprise an ejection capsule 204, which is configured to eject or release the memory tags (e.g., RFID tags). The ejection capsule 204 may be operated by a hydraulic, mechanical, or electrical mechanism. In accordance with some embodiments of the invention, the RFID or memory tags may be able to store a certain amount of data before release, for example up to 1 week of 24 hours of data at 1 second intervals. The writer may be designed to function downhole and the reader may be designed to function downhole or at the surface flow line. A downhole clock/counter 205 may be used to correct or remedy the effects of the time delay between data acquisition and reading.

Multiple devices may be operated simultaneously in wells/laterals. The devices may be used where permanent gauges have failed or in a lateral or multiple laterals simultaneously. Since the sizes and structures of oil wells and laterals may differ, the need for well monitoring may be different for each structure. The construction of a measurement device may be altered for different situations.

FIG. 3 shows another measurement device, which may be used in downhole retrofit production monitoring. As shown in FIG. 3, the measurement device 300 may have a nipples or latches 301 to engage a casing or tubing 303. This measurement device is a variant of the device shown in FIG. 2. The measurement device 300 may contain one or more components 303 selected from: pressure and/or temperature sensors, battery, clock, RFID receiver/transmitter, etc. The measurement device 300 may be self propelled and/or be programmed to descend to a particular depth or location. The measurement device 300 may include a plurality of releasable RFID tags or memory tags configured to store information from the sensors. The RFID tags or memory tag may be released or ejected in the flow stream to travel toward the surface of the well system.

Referring to FIG. 4, which shows an illustrative embodiment of simultaneous use of multiple downhole measurement devices described in FIG. 3. As shown in FIG. 4, the multiple downhole measurement devices 409 may be deployed though an existing upper completion tubing 401. The existing upper completion is deployed in a casing 403. The completion may include a surface controlled sub-surface safety valve (SCSSV) 402 and one or more permanently installed sensor devices 404, which may include memory tags that can record measurements and be released on demand by signals sent from surface.

A production deflector 406 is used to drill a lateral from the main-bore. The lateral completion may be anchored to the upper completion using a ported packer 405. In some embodiments, other methods of well construction may be used in the lower completion such as a slotted liner or a cemented and perforated liner. The lower completion may include swell packers 408 and inflow control device (ICD) stations with screens 407. One or more measurement devices 409 (as described in FIG. 2 or 3) are shown as being deployed throughout the lateral completion. As shown, the measurement devices 409 may be able to record the contribution of each of the multiple zones of production, indicate the individual production rates, identify the location of water breakthroughs, etc.

The measurement devices in accordance with embodiments of the invention may be sent into a wellbore and be carried to the desired locations (depths) by the downward fluid flows or by gravity. Alternatively, such measurement devices may have the ability to self-propel to the desired locations. Furthermore, some of these devices may have the steering ability such that they can be controlled to enter selected laterals.

FIG. 5 shows an example of a measurement device 500 having the ability to self-propel and/or steer according to one embodiment of the invention. In this particular example, the measurement device 500 has a substantially truncated cone shape (or dart shaped). However, one skilled in the art would appreciate that a device in accordance with embodiments of the invention may also adopt other shapes. Diagram (A) shows a side view and Diagram (B) shows a top view of the measurement device 500. The measurement device 500 may include a self-propel mechanism 502 and a steering mechanism 505 such that the device can self-propel and self-steer to the desired locations. The measurement device also includes an ejection module/carrier 501 for carrying and releasing multiple RFID or memory tags. In addition, the measurement device 500 may include a plurality of sensors 506, which may be SOI or MEMS sensors. The measurement device may optionally include an inflatable or anchor device 504 for lodging itself in the well.

Furthermore, the measurement device may also include a memory 507 for storing a program to control the sensor measurements and/or ejection module. In accordance with embodiments of the invention, the memory 507 may be reprogrammable such that the event logics can be changed when necessary. Any method known in the art may be used to change the program in the memory, for example by sending a signal from the surface downhole or by flowing an RFID tags by the device.

The device may be battery-operated so that it can reach a predetermined depth, and the device may be constructed and programmed to self-navigate to enter the well (e.g., a lateral leg) to reach anywhere in the well, or to be fixed at the bottom of the well. Advanced smartness can be built into the device to expand its intelligence, so that it may have depth-recognition, find and steer its way into multi lateral legs, or continuously sweep the producing formation to log the inflow areas. After reaching the desired depth, the device may set or lock itself in a location, for example, by extending or inflating anchor device 504 (see FIG. 5(C)). In accordance with some embodiments of the invention, the device may be programmed with pre-determined logic that enables the device to carry out self-alignment and depth-correlation.

Once at the desired location, the device may automatically begin the process of data logging and storing data. Various well conditions, formation properties, or fluid properties may be measured. In addition, fluid velocity and flow may be measured, for example, using flutes on the tool's surface. The device may send the data-containing RFID tags or memory tags from ejection module/carrier 501 into the fluid flow to send the memory tags uphole.

In accordance with embodiments of the invention, the memory tags are configured or selected such that they can float in the fluids expected in the well. If low flow rates are expected, buoyant RFID tags or memory tags may be used to ensure that they travel to where the tag reader is located or to the surface. Furthermore, the memory tags may include a drag or similar devices such that they will pass the reader in a known orientation. The RFID tag or memory tag reader may capture the well or fluid data in the well or at the surface, as the tags flow by. Alternatively, the tags may be captured by a strainer device in the flow line and be read later.

Turning to FIG. 6 which is a flow chart illustrating a method for monitoring and collecting well parameters by using a downhole measurement device in accordance with embodiments of the invention. In accordance with this method, a measurement device of the invention may be deployed downhole (step 61). The measurement device will include one or more sensors for obtaining well or fluid parameter data (step 62). After obtaining said well or fluid parameters data, the measurement device may write the measured data onto one or more RFID tags or memory tags (step 63). The memory tags are carried in an ejection module. The measurement and recordation may occur at a predetermined time and rate or at the occurrence of certain events, as described above. The ejection module may be configured to release or eject the said data-containing memory tags into the flow at a predetermined rate or based upon some other criteria when the operation is completed or after a certain amount of data has been written to the RFID tags or memory tags (step 64). The released tags may be carried toward surface along with the flow. The released tags may pass a tag reader anywhere along the flow line or at the surface. The reader may then gather data or automatically upload the acquired data to a processing or handling system (step 65).

This process may be carried out on a continuous basis until the RFID or Memory tags have been exhausted in the tool or the battery life is expended. Once the supply of stored RFID or Memory tags is exhausted, the device may be retrieved or allowed to remain in the well, and another device may be sent downhole to continue the measurement process. A reader in the flow line at the wellhead or on a process line may acquire (read) the data as the RFID tags or memory tags pass by or after the memory tags are captured in a strainer device. The reader may send the data to an acquisition or processing system for data analysis and processing.

While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. 

1. A downhole measurement device, comprising: one or more sensors configured to measure a parameter in a well; a plurality of memory tags for storing measurement data from the one or more sensors, wherein the plurality of memory tags are configured to be carried by a fluid flow uphole; and an ejection module configured to release one of the plurality of memory tags upon a predetermined condition.
 2. The downhole measurement device of claim 1, wherein the plurality of memory tags are radiofrequency identification (RFID) type memory tags.
 3. The downhole measurement device of claim 1, further comprising a self-propel mechanism.
 4. The downhole measurement device of claim 3, further comprising a steering mechanism.
 5. The downhole measurement device of claim 1, wherein the one or more sensors comprise one or more of a pressure sensor, a temperature sensor, a vibration sensor, a flow sensor, a chemical gauges, or a combination thereof.
 6. The downhole measurement device of claim 1, further comprising a mechanism for anchoring itself in the well.
 7. The downhole measurement device of claim 1, wherein the downhole measurement device has a dart or plug shape.
 8. The downhole measurement device of claim 7, wherein the downhole measurement device comprises a channel to allow a fluid to flow through the downhole measurement device.
 9. The downhole measurement device of claim 1, further comprising a memory storing a program for controlling data measurements and/or ejection of the plurality of memory tags.
 10. The downhole measurement device of claim 9, wherein the memory is reprogrammable.
 11. A method for monitoring a well or fluid parameter in a wellbore, comprising: deploying of a downhole measurement device having one or more sensors and a plurality of memory tags, wherein the deploying is by allowing the downhole measurement device to be carried by a fluid into the wellbore; obtaining measurement data of the parameter using the one or more sensors; writing the measurement data to one of the plurality of memory tags; releasing the memory tag having the measurement data; allowing the memory tag having the measurement data to be carried by a flow in the wellbore uphole; reading the measurement data from the memory tag having the measurement data at a location remote from the downhole measurement device.
 12. The method of claim 11, wherein the deploying is to a lateral leg in the wellbore.
 13. The method of claim 12, wherein the deploying uses a self-propel mechanism on the downhole measurement device to enter the lateral leg.
 14. The method of claim 11, wherein the obtaining the measurement data is control by a program stored in a memory in the downhole measurement device.
 15. The method of claim 11, wherein the deploying results in the downhole measurement device being lodged at a predetermined depth in the wellbore. 